Method of making cutting, scoring and embossing die set

ABSTRACT

A die set for cutting, scoring and embossing sheet material comprises a first die having cutting rules, scoring rules and embossing means attached to a base, a mating die cooperating with the first die having mating embossing means for cooperating with the first embossing means on the first die and registering means on the first die and the mating die for ensuring proper registration of the first embossing means and the mating embossing means.

BACKGROUND OF THE INVENTION

The present invention relates to improvements in steel rule die sets ofthe type used in cutting out, scoring and embossing box blanks fromsheets of paper, plastic or the like.

The present invention is an improvement over the invention disclosed andclaimed in U.S. Pat. No. 3,863,550 of Sarka and Kang, of which thepresent applicant is a co-inventor. The invention of that patentovercame disadvantages enumerated therein of prior art cutting andscoring dies.

A problem still exists where it is desired to cut out, score and embossa plurality of box blanks. It is very difficult and tedious to align theembossing means to produce an embossment properly positioned withrespect to printing or other ornamentation on the box blanks. It hasbeen necessary to carefully measure, place and secure the male andfemale embossing elements in exact alignment on the male and female diemembers. Where a plurality of cutting, scoring and embossing dies arelocated on a single die support for simultaneously cutting, scoring andembossing a plurality of relatively small blanks, the time required toalign the male and female embossing members is substantial. Moreover,inaccuracies are possible because of the large number of adjustmentswhich are necessary.

British Patents Nos. 1,060,111 and 1,060,313, both issued to AmericanCan Company, disclosed the use of a male embossing element with acutting and scoring die set. The male embossing element does not matewith a rigid female embossing elements. Rather, the male embossingelement operates in conjunction with a resilient insert attached to thedie plate or the press.

It is well known that in order to obtain a sharply defined embossment arigid male embossing member must cooperate with a rigid female embossingmember. To ensure this cooperation, exact alignment of the rigidembossing members is necessary.

SUMMARY OF THE INVENTION

The present invention overcomes the problems of the prior art byproviding a simple, accurate means for aligning male and femaleembossing means attached to cutting and scoring dies or which areintegrally formed as a part of the cutting and scoring dies.

The present invention comprises a cutting, scoring and embossing die setcomprising a first die having a base which includes cutting means,scoring means and first embossing means (which may be either a female ormale embossing element), a mating die having a base including means forcooperating with the cutting means and the scoring means of the firstdie, mating embossing means (a female embossing element if the firstembossing means is a male element, or vice verse) for cooperating withthe first embossing means, and registering means associated with thefirst die and the mating die for ensuring proper registration of thefirst embossing means and the mating embossing means.

As used in this specification and claims, the word "emboss" and all ofits derivatives includes both embossing and debossing processes. A sheetis embossed when portions thereof are raised in relief from thesurrounding surface. A sheet is debossed when portions thereof aredepressed below the surrounding surface. Thus, an embossment may becomea debossment merely by changing the relationship of the male embossingmember and the female embossing member or by inverting the sheet.

The drawings forming a part of this specification, and the descriptionthereof illustrate a die for use in a flat press. This is merely forpurposes of illustration. The present invention encompasses the use ofcutting, scoring and embossing dies on platen presses, rotary presses oron any other suitable presses.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of illustrating the invention, there is shown in thedrawings a form which is presently preferred; it being understood,however, that this invention is not limited to the precise arrangementsand instrumentalities shown.

FIG. 1 is a partial bottom plan view of a die showing a plurality ofrepetitive cutting, scoring and embossing means in accordance with thepresent invention.

FIG. 2 is a partial sectional view of a cutting, scoring and embossingdie set in accordance with the present invention, the sectional view ofthe upper die being taken along line 2--2 of FIG. 1.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to the drawings in detail, wherein like numerals indicate likeelements, there is shown in FIG. 1 a die 10 comprising a plurality ofcutting, scoring and embossing means to cut, score and emboss a sheet,forming a pluraltiy of embossed box blanks. The sheet may be made ofcoated or uncoated paper products, plastic material metal or any othertype of sheet material which may be formed into scored and embossedblanks, for example, cigarette box blanks.

Although a plurality of substantially identical repetitive cutting,scoring and embossing means are illustrated as being attached to the diebase or support 12 in FIG. 1, only one will be described in detail forpurposes of illustration.

With reference to FIGS. 1 and 2, a die support or base 12 comprises anysuitable substantially dimensionally stable plates 14 and 16 separatedby an intermediate semi-rigid plastic material 18 therebetween. The base12 can be any solid mterial such as metal or plastic.

Cutting rules 20 and scoring rules 24 are inserted in slots in base orsupport 12 and affixed thereto by means of the semi-rigid plasticmaterial 18 or other suitable means. Cutting rules 20 have a pointededge 22 for cutting the sheet material. Scoring rules 24 have a blunt orrounded edge 26 for scoring the sheet material.

Die 10 is shown as the upper die in FIGS. 2. It is not neccessary thatdie 10 be the upper die. Thus, die 10 can be the fixed die or themovable die, the upper die or the lower die in the die set.

The attachment of cutting rules 20 and scoring rules 24 to base orsupport 12 and the construction of base or support 12 is in accordancewith the "Cutting and Scoring Die" disclosed in U.S. Pat. No. 3,863,550of Sarka and Kang, issued Feb. 4, 1975 to ChemPar Corporation, thedisclosure of which is hereby specifically incorporated herein byreference. The materials and method of construction used in making thepresent invention may be the same as those disclosed in U.S. Pat. No.3,863,550.

Die 10 also includes mounting block 28 on which an embossing element 32is mounted, preferable by means of adhesive 44. Mounting block 28 issecured in die support or base 12 by the semi-rigid plastic material 18.Anchors 30 aid in securing mounting block 28 to base 12. Mounting block28 fits in apertures 15 and 17 in plates 14 and 16, respectively. Theapertures may be formed by a photochemical etching method as describedin U.S. Pat. No. 3,863,550 or may be drilled, stamped or otherwiseformed in the plates. Mounting block 28 is adjusted within base orsupport 12 so as to be at least approximately aligned with embossingelement 50 of mating die 46.

Embossing element 32 as illustrated in FIG. 2 is a female embossingelement. Recesses 34 and 36 represent any suitable designs to beembossed in the sheet material. As illustrated in FIG. 1, the designsrepresent, for example, the numerals "1" and "4".

Embossing element 32 and mounting block 28 may be made of any suitablesubstantially dimensionally stable material, including, for example,copper, brass, magnesium, aluminum and, preferably, steel. Othersubstantially rigid and substantially dimensionally stable materials,such as some plastics, may be used to form mounting block 28 andembossing element 32. The type and thickness of the sheet material beingembossed will determine the type of material used to make mounting block28 and embossing element 32. It is presently preferred to mountembossing element 32 on mounting block 28, rather than mountingembossing element 32 directly onto plate 14, so that the properpositioning and strength can be achieved as well as reducing the changesthat die base or support 12 will become warped after repeated cutting,scoring and embossing operations.

Flange 38 is integrally and frangibly attached to embossing element 32.Flange 38 contains an aperture 40 which acts as a registering means whenmated with registration post 56 on mating die 46. A U-shaped channel 42is provided between flange 38 and embossing element 32 so that flange 38may be easily removed, such as by snapping the flange 38 from embossingelement 32 along weakened channel 42. Flange 38 is removed afterembossing element 32 is securely affixed to mounting block 28 followingexact registration of embossing element 32 with mating embossing element50 on mating die 46.

Mating embossing element 50 is illustrated as being a male embossingelement having projections 52 and 54 adapted to mate with recesses 34and 36 on female embossing element 32. Male embossing element 50,registration post 56 and recess 48 may be integrally formed in matingdie 46 by a photochemical etching process or may be attached to matingdie 46 by any other suitable method. Die 46 may be made of a highstrength material such as a hard steel alloy plate. Preferably, recess48, embossing element 50 and registration post 56 are integrally formedin die 46.

The method of registering the embossing elements and affixing embossingelement 32 to mounting block 28 is as follows.

Die 10 is formed as described above the reference to U.S. Pat. No.3,863,550. Die 46 preferably is formed by photochemically etching recess48, embossing element 50 and registration post 56 in a steel plate.

Any suitable design is formed in embossing element 32 such thatembossing element 32 mates with embossing element 50. A U-shaped channel42 is formed between flange 38 and embossing element 32. Registrationhole 40 for mating with registration post 56 is also formed in flange38.

Embossing element 32 is placed in contact with embossing element 50 sothat the embossing elements are in perfect registration. This is shownin phantom in FIG. 2. Any suitable adhesive 44 is then applied bybrushing, spraying, or any other suitable means to either the uppersurface of embossing element 32 or the lower exposed surface of mountingmember 28. For purposes of illustration, the thickness of adhesive 44has been greatly exaggerated. The preferred adhesive is an epoxy resinwhen mounting block 28 and embossing element 32 are made of steel. Anysuitable adhesive or other means of attaching embossing element 32 tomounting block 28 may be used, depending upon the characteristics ofmounting block 28 and embossing element 32.

Die 10 is then lowered onto die 46 in perfect registration by standardmethods of aligning and registering dies. During this step, illustratedin phantom in FIG. 2, mounting block 28 is maintained in contact withadhesive 44 on embossing element 32 and the adhesive is allowed to cure.By this means, element 32 is securely attached to mounting block 28.

Die 10, now including embossing element 32 securely attached to mountingblock 28, is then removed from die 46. Flange 38 is separated fromembossing element 32 along the U-shaped channel 42 so that it does notinterfere with the embossing operation. The cutting, scoring andembossing dies are now ready for use.

It is to be appreciated that the greatest time and labor savings will beachieved when a plurality of embossing sets are required. When smallblanks are being produced, as many as fifty to one hundred or moreembossing sets may be required. A plurality of embossing elements 32 maybe separately produced and placed in aligned relationship withrespective embossing element 50.

The registering posts and holes will ensure proper positioning andalignment of each embossing set. Adhesive may be applied so that allembossing elements 32 are secured at the same time to mounting blocks28.

The present invention may be embodied in other specific forms withoutdeparting from the spirit or essential attributes thereof and,accordingly, reference should be made to the appended claims, ratherthan to the foregoing specification as indicating the scope of theinvention.

I claim:
 1. A method of forming a cutting, scoring and embossing die setcomprising the steps of:(a) forming a first die by:(1) forming slots andan aperture in a support for a cutting rule, a scoring rule and amounting block, (2) inserting a cutting rule and a scoring rule in theslots and inserting a mounting block in the aperture; (3) attaching thecutting and scoring rules and the block to the support, and (4)providing first embossing means for attachment to the mounting block;(b) forming a mating die including mating means for cooperating with thecutting and scoring rules and mating embossing means for cooperatingwith the first embossing means on the first die; (c) registering thefirst embossing means of the first die with the mating embossing meansof the mating die; and (d) securing the first embossing means to themounting block while the first embossing means and the mating embossingmeans are in registration.
 2. A method according to claim 1 furthercomprising aligning the mounting block in the aperture in at leastapproximate alignment with the mating embossing means of the mating die.3. A method according to claim 1 including providing the first embossingmeans with a first portion of a registering means, providing the matingembossing means with a mating portion of a registering means andaligning the portions.
 4. A method according to claim 3 includingintegrally forming the mating portion of the registering means on themating die.
 5. A method according to claim 3 including removing thefirst portion of the registering means from the first embossing meansafter securing the first embossing means to the block.
 6. A methodaccording to claim 4 wherein the registering step (c) includes placingthe first portion of the registering means in mating contact with themating portion of the registering means, and the securing step (d)includes applying adhesive to at least one of the adjacent surfaces ofthe first embossing means and the mounting block, aligning the first diewith the mating die, lowering the first die onto the mating die suchthat the mounting block and the first embossing means are adhesivelybonded together and allowing the adhesive to cure.